RAPID ASSESSMENT OF ELECTRIC SUPERCHARGER SYSTEM...

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Alessandro Renna Daniel Baumann, IT AVL Powertrain UK Ltd. Confidential RAPID ASSESSMENT OF ELECTRIC SUPERCHARGER SYSTEM LAYOUTS FOR ENGINE DOWNSIZING Electronics & Controls Department 28 th /29 th October 2015 National Motorcycle Museum, Solihull

Transcript of RAPID ASSESSMENT OF ELECTRIC SUPERCHARGER SYSTEM...

Alessandro Renna

Daniel Baumann, IT

AVL Powertrain UK Ltd.

Confidential

RAPID ASSESSMENT OF ELECTRIC SUPERCHARGER

SYSTEM LAYOUTS FOR ENGINE DOWNSIZING

Electronics & Controls Department

28th/29th October 2015

National Motorcycle Museum, Solihull

Alessandro Renna | | 26 October 2015 | 2 Confidential

AGENDA

1. Engine downsizing

2. Simulink MVEM

3. Steady – State validation

4. EDS effect i. Steady – State

ii. Transient Response

iii. Vehicle Response

5. Conclusions

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ENGINE DOWNSIZING

• Engine downsizing to reduce fuel consumption and CO2 emissions

• Superchargers and turbochargers can recover BMEP reduction

• Turbochargers have slow transient response (turbo lag) and compressor surge limits air mass filling and torque at low speeds

• Electric driven superchargers (EDS) can provide good boosting particularly at low engine speeds without taking power from the engine (mechanical supercharger solution)

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SIMULINK MVEM

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SIMULINK MVEM: CYLINDERS

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SIMULINK MVEM: RESTRICTION

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SIMULINK MVEM: ADIABATIC PIPE

Rm

pVT

WWdt

dm

HHVc

R

dt

dp

p

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21

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SIMULINK MVEM: CHARGING ELEMENTS

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SIMULINK MVEM: SHAFT, AIR COOLER

)( ambininout TTeffTT dt

dJbTQTQ outin

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SIMULINK MVEM: CONTROLLERS

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STEADY – STATE VALIDATION (ONLY TURBOCHARGER)

• Based on real WOT performance for a 1.0L engine with one turbocharger and one after-cooler.

• Reference pressure for waste-gate controller has been set equal to experimental values.

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EDS LAYOUTS

Based on validated TC model (only turbocharger), several combinations of turbocharger, electric supercharger and additional inter-cooler have been investigated.

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STEADY – STATE: COMPARISON

• Full load simulations with predefined PR set-points.

1

1

PRTWcP inp

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STEADY – STATE: COMPARISON + IC

• Full load simulations with additional inter-cooler and the same predefined PR set-points.

1

1

PRTWcP inp

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STEADY – STATE: COMPARISON

IC

IC IC

IC

refin

refin

corrpp

TTWW

/

/

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TRANSIENT RESPONSE

Transient response at fixed engine speed of ETC, TEC, ECTC and TCEC versus only TC model has been simulated using 2 step signals:

• Throttle tip-in to 100%;

• Electric motor torque for EDS from 0 to 1 Nm;

• Motor is disconnected for EDS PR set-points equal to 1.

EDS and turbocharger inertias are set equal to 5E-05 kg*m2.

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TRANSIENT RESPONSE: COMPARISON

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TRANSIENT RESPONSE: COMPARISON W/ IC

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VEHICLE RESPONSE

dt

dvMFFFF v

vgraderollairt

sin

cos

2

1 2

gMR

gMCR

vACR

vgrade

vrroll

vfrontaldairair

iTQR

F

ivR

n

eng

w

fric

t

veng

2

60

ηfric i Rw Mv Afrontal ρair Cd Cr ϑ

0.8 4 0.3 [m] 1200 [kg] 2 [m2] 1.2 [kg/m3] 0.4 0.015 0 [deg]

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VEHICLE RESPONSE: COMPARISON

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VEHICLE RESPONSE: COMPARISON + IC

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CONCLUSIONS - 1

Steady – State simulations showed:

• EDS can completely recovers the WOT torque deficit at low speeds and its position is not relevant to reach the nominal engine torque

• EDS in 2nd stage can extend the range of use from 1700 rpm to 3200 rpm but with increase of electric power request

• EDS wheel in TEC is more stressed at higher temperatures, so it needs better thermal characteristics and hence more expensive

IC

IC

IC

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CONCLUSIONS - 2

Transient simulations showed:

• Transient reduction of turbo lag during acceleration

• ETC and TEC models have basically the same trend

• Vehicle dynamic during tip-in manoeuvre improved without any significant influence of the EDS position

IC

IC

IC

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CONCLUSIONS - 3

Use of additional air cooler between the compressors showed:

• Extra increase of WOT torque with the same boost conditions

• Reduction of second stage temperatures

• No improvement of acceleration lag; it just moves operating points of the first stage compressor far from surge.

• Weight, volume and costs of the engine increase

IC

IC

IC

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